Download - WW F&B Mtg_NA Wine Making
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Learnings from a Key North American
Winery
Millipore Food & Beverage Annual Meeting, July 2006, Molsheim
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Corporate Overview
Worlds largest Winery* by both volume of wine produced and wine sales Estimated 20%WW market share
Worlds largest Brandy producer
Supplier: Concentrate
Crowns, Closures, Cases, Bottles, Labels
Neutraceutical & Vitamins
Crops (sweet potatoes, watermelons, grains, corn, etc)
Purchases a significant quantity of grapes from CA, AZ farmers based on 10-15year contracts
Owns and operates its own sales, warehousing and distribution networks acrossthe world. Self-owned distributors in 49 of 50 US states (NOT MASS!).
Real financials difficult to estimate
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Brands
Gallo of Sonoma
Turning Leaf
Turning LeafCoastal Reserve
Carlo Rossi
Peter Vella
Boones Farm (Malt)
Bartles and Jaymes (Malt)
Burlwood
Ecco Domani
DaVinci
Marcelina Vineyards
Napa Valley Vineyards
Patriarch (Brandy)
E&J Brandy Lines (Brandy)
VSOP
VS
XO
Cognac
White Brandy Ballatore (Champagne)
McWilliams
Hanwood
Bridlewood
Louis M. Martini
Frei Brothers Reserve
Mirassou
Redwood Creek
Gallo Family Lines
Twin Valley
Single Vintage
Sonoma Reserve
Estate Series Anapamu
Gossamer Bay
E&J Cask & Cream (Spirit)
Caramel Temptation (Spirit)
Chocolate Temptation (Spirit) Indigo Hills Blanc de Blancs
(Champagne)
Winking Owl
Hornsby Draft & Ciders (Malt)
Rancho Zabaco
MacMurray Ranch
Indigo Hills
Black Swan
Whitehaven
Red Bicyclette
Cooperage by E&J Gallo
Night Train (Spirit)
Totts (Champagne)
Livingston Cellars Liberty Creek Wild Vines Bella Sera WilliamWycliff Barefoot Cellars Thunderbird (Spirit)
Andre (Champagne)
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Operations Overview
Modesto
Central Coast, Northern CA
Central Valley
International Operations
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Modesto Operations
Bottling Department 17 Bottling Production Lines
16 Filtration Skids
6 12-Round 30 Housings per Filtration Skid (3,456 10 elements)
Two Identical Sets of one 0.5-0.65 um Prefilterhousing followed by two 0.45 um finalfilter housings in series (redundant final filtration)
Flow rates range from 25 to 160 gpm Millipore filters (Bevigard M, Vitipore II Plus) used on high volume, high flow lines
Pall Ultipor used on lower flow, not as utilized lines
All production lines currently involved in 7 yr $100M Modesto renovation. Filtrationskids will be upgraded with more automation and proper sizing tied to flow rate andhistorical performance
Production Water Systems Filtered Hot and Cold CIP / RinseWater
8 12-Round 30 Housings
24-hour recirculating 180 F (82 C) hot water line uses Vitipore II, much longer servicelife than competitors, first Gallo process filters to switch over to Millipore.
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Modesto Operations
Brandy Dept.
Three Brandy production lines, no membrane filtration
Wine Making / Process Technology Dept.
R&D /Winemaking specialty line, no membrane filtration Cellar Dept.
RO Units
8 Pall OenoFlow cross flow systems being installed to replace
existing pressure leaf (Est. $10+M project) No filtration at other Modesto facilities; Closures, Cases
& Labels, Glass
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Central and Northern Coast Operations
Sonoma
One production line w/ microfiltration
Demo-ing Pall Crossflow in 2005 as replacement to plate and
frame
Martini
One current production line w/ microfiltration
Installation of second show production line underway
Bridlewood and Other Boutique
Mobile bottling Many mobile bottlers use Millipore
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Central Valley Operations
Crush Facilities
Livingston Winery
Crushes 450,000 tons annually (~83.25 MG)
FresnoWinery Crushes 650,000 tons annually (~120.25 MG)
About to begin trialing Pall Crossflow as replacement to
12-16 pressure leaf filters
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Central Valley Operations
Other Facilities
GVI Vineyards, farming, waste treatment
PilotWinery Full sized winery for specialty winemaking/R&D
McCall Brandy High end brandy facility
Barefoot Cellars New purchase, production being moved toModesto
GrapeCo New acquisition, supplement concentrate
SJVC Primary concentrate facility
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Central Valley Operations
Neutraceutical & Extraction Facilities
Activin, antioxidant recovery from seeds/skins
Wine production of lesser quality, high demand products with
insufficient vineyard planting (i.e. Pinot Noir, White Zinfandel)
through extraction techniques (also to supplement low quality highvolume common white wines)
Tartaric Acid plant located at Livingston
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International Operations
Partnerships with InternationalWineries
Some R&D, Engineering,Winemaking Support
Products are Marketed, Sold, Distributed as Gallo Products
Some are bottled in Modesto, some bottled at home winery
Italy Ecco Domani
DaVinci Bella Sera
France Red Bicyclette
Australia Black Swan
McWilliams / Hanwood
New Zealand Whitehaven
Chile Joint wine-making with one, future plans not announced
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Process Flow
Fermentation Centrifuge
Final Blending &Stabilization
(or aging if high end)
Initial Blending
&
Stabilization
Rough DEFiltration
(Skip if high end)
Polish DE Filtration(Plate & Frame
Pad if high end)
Microfiltration
& Bottling
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Process Flow
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Detailed Modesto Operations
Filtration Skid Sanitation
Every product change requires changing to second filtration set. Old units are blown dry with N2, cold rinsed, hot water back-flushed, cold water
rinsed, integrity tested and sealed (a filter set could see 7-12 per week)
Certain product changes involve hot or cold water rinses of filler --
water sent through new filter set Full hot water sanitation (forward direction) performed on start-up, shut
down of line, periodic intervals for sensitive varietals
Monthly 1% NaOH caustic treating of fillers and piping Housings are bypassed
Tri-monthly caustic treating of lines, fillers, housings Filters are removed
All water is 0.45 um filtered, with ClO2 added at 50 ppm ClO2 tested as compatible with Durapore
Housings are sometimes filled with Divosan (used to use Oxonia) forweekend shut down
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Detailed Modesto Operations
Plugged Housings
Units plug and second set is immediately put in-line
Less than 5 minutes back in production
Plugged units are N2 blown dry, cold water rinsed, hot water back-
flushed, cold water rinsed, integrity tested and sealed Filters are regenerated and re-used until (1) housing fails IT or (2)
pluggage occurs after < 2 hrs of production on a set w/o being
obviously faulty wine (typically the latter)
Product Issues
Difficult to filter products run through both sets of units in parallel toreduce per filter flowrate, throughput (ex. Hornsby, Sangria)
Most commonly plugged product is Champagne
Flavored wine (i.e.Wild Vines not wine coolers), difficult to filter
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Detailed Modesto Operations
Filtration Considerations
All points in process have reclaim; manage which areas are
re-combined, refiltered at microfiltration skid, sent back to
tank farm
ClO2 has some flavor concerns with wine coolers
Citric Acid rinse used to mitigate
Pumps, filler feed valve radio controlled to filler operation to
control flow rates and water hammer
End of tanks closely monitored; no N2 blanketing leads toincreased dissolved O2, plugging due to microbial growth &
surface films
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Detailed Modesto Operations
Filtration Considerations Cont
Perform DE filtration (clarification) at coldest possible temperature -
- cooling during final filtration can cause precipitates
Monitor filler overflow -- refiltration can lead to significantly lower
final throughputs
Frequently vent housings, particularly on carbonated products
Avoid product topping off or mixing after DE or rough filtration. Even
mixing same wine types & vintage can lead to interactions and
create precipitates
Wine makers have 0.65 um membrane available for high end
products. No rule for selection, wine maker decision. Estimate 1%
of bottling runs use 0.65 um.
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Detailed Modesto Operations
In-Line Blending
Move away from large scale (600K) tank blending of malt-
based wine coolers
Combine feed streams just prior to filtration skid andcarbonate
Dry flavors added to RO water then mixed with malt alcohol, liquid
flavors, carbonated, SO2 added, filtered and cloud added
Preliminary tests showed no effect on filterability
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Future Operational Plans
Family has Expressed Desire to Build Winery of the
Future
Combine Central Valley facilities
Current interest centered around R&D, high technologywinemaking not economically feasible given location and
existing capital constraints (have list of technologies)
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Future Operational Plans
Many Renovation & Expansion Projects Underway
Ultra Low Cost Component Wine-making Initiatives
Use technology to beat out 2 buck chuck competitors
Water + recovered grape alcohol + pomace extractedflavor & aroma compounds = wine targeted at 30-50%
production costs of current bulk jug products
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Future ofProducts
Ultra-low cost wines
Mid/High end range less common varietals
Increased US focus on marketed foreign wines
Malt wine cooler & wine based beverage sales have flat-lined in US; still
strong in South America, Asia Dessert wine (port, sherry) sales continue long time decreasing trend
Fight off pressures from China
25 % increase in Chinese wine production & winery capacity eachyear for past 4 years
Current products not considered acceptable to US tastes Low cost grape alcohol products
US regulations state alcohol used in wine, wine based spirits, brandy mustoriginate from grape fermentation; leads to Gallo dominance in these markets
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Questions?